Analysis and prediction of maximum contact stress and depth by ultrasonic surface rolling with elastic–plastic theory

Ultrasonic power plays an important role in ultrasonic surface rolling, and the maximum contact stress and springback generated by ultrasonic power during ultrasonic rolling also affect the surface quality of mechanical materials. In order to study the effect of different ultrasonic powers on the maximum contact stress and springback during the ultrasonic rolling process, in this paper, based on the elastic–plastic theory, a mathematical model for predicting the maximum contact stress and springback is proposed. In order to verify the mathematical model, the ultrasonic surface rolling experiment was carried out with 20 steel as the experimental sample. Through the analytical derivation of the mathematical model, and study other characteristic parameters of the model, such as rolling depth, Mises. And the ultrasonic surface rolling process is simulated numerically by ABAQUS. The results show that the mathematical model can effectively predict the maximum contact stress, rolling depth, Mises, and springback, and the average deviation is 10%. With the increase of ultrasonic power, Mises, pressure, and springback gradually decrease, and the rolling depth increases.